Motorized fluid sprayer

This application claims benefit of and priority to U.S. Provisional Application Ser. No. 63/267,903 filed Feb. 11, 2022 entitled Man Portable Decontamination Sprayer, which is hereby incorporated herein by reference in its entirety.

Portable motorized fluid sprayers are used to distribute a variety of different fluids for many different purposes. For example, some portable motorized fluid sprayers may be used to spray water or chemicals, such as pesticides. Some portable motorized fluid sprayers are relatively small and may fit on a user's back while other portable motorized fluid sprayers may be somewhat larger and therefore too large for mounting on a human.

Most motorized fluid sprayers are intended for home or commercial uses and therefore are often not suitable for more demanding military use. For example, military equipment may sometimes be deployed from aircraft to areas without power infrastructure and is sometimes used with decontamination solutions. Hence, what is needed is an improved motorized fluid sprayer that is better equipped to operate with military usage.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer including: a fluid tank configured to contain fluid; and, a pump manifold including a pump, an electric motor operatively coupled to the pump, and a controller operatively connected to the electric motor; and, a fluid conveying structure hydraulically connected to the pump; wherein the controller is configured to operate the motor to pump fluid from the fluid tank out of the fluid conveying structure.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump is a gear pump.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump manifold is removably connected to the fluid tank.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, further including a support structure removably connecting the fluid tank to the pump manifold.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the support structure includes a bracket or shelf and wherein the pump manifold is connected to the support structure via one or more of latches, mating grooves, mating pins/holes, screws, and bolts.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the support structure is permanently fixed to the fluid tank or is removably connected to the fluid tank.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump manifold is configured to drain fluid from a fluid container when disconnected from the support structure and the fluid tank.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the fluid tank is at least partially composed of flexible material and may have an expanded configuration and a compressed configuration that is thinner than the expanded configuration.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump manifold has a first mode of operation spraying fluid from the fluid tank out of the fluid conveying structure, and a second mode of operation suctioning fluid from the fluid conveying structure into the fluid tank.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump manifold has a first mode of operation spraying fluid from the fluid tank out of the fluid conveying structure, a second mode of operation recirculating fluid from a first opening of the fluid tank to a second opening of a fluid tank.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump manifold is configured to pump fluid a predetermined pressure to the fluid conveying structure without regard to a viscosity of the fluid.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the pump manifold further includes an inline pressure sensor arranged to sense pressure within a hydraulic passage of the pump manifold.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the fluid conveying structure further includes a handle having a trigger and a trigger sensor configured to sense a position of the trigger; wherein the controller adjusts a speed of the electric motor based on trigger sensor data from the trigger sensor and from pressure sensor data from the inline pressure sensor.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the handle further includes a safety lever; wherein the controller prevents spraying from the fluid conveying structure until the safety lever is actuated.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the handle further includes a safety lever; wherein the safety lever removably engages a portion of the trigger to maintain a position of the trigger until the safety lever is depressed.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the handle further includes a maximum flow rate interface; wherein the controller limits a maximum flow rate during spraying from the fluid conveying structure based on a position of the maximum flow rate interface.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the handle further includes a flow rate knob having a shoulder portion that moves closer to or away from a portion of the trigger so as to limit a maximum position of the trigger.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein the controller adjusts a direction of rotation of the electric motor based on trigger sensor data from the trigger sensor.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, wherein moving the trigger closer to the handle causes the portable motorized fluid sprayer to spray out fluid from the fluid conveying structure and wherein moving the trigger away from the handle causes the portable motorized fluid sprayer to suction fluid into the fluid conveying structure.

In some aspects, the techniques described herein relate to a portable motorized fluid sprayer, further including two shoulder straps configured to support the portable motorized fluid sprayer on a back of a user.

In some aspects, the techniques described herein relate to a method of operating a portable motorized fluid sprayer, including: sensing a position of a trigger of the portable motorized fluid sprayer; converting the sensed position of the trigger to an intended fluid pressure value; measuring pressure within a hydraulic passage of the portable motorized fluid sprayer; and, activating and adjusting a speed of a pump of the portable motorized fluid sprayer until the pressure within the hydraulic passage reaches the intended fluid pressure value.

Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.

While different embodiments may be described in this specification, it is specifically contemplated that any of the features from different embodiments can be combined together in any combination. In other words, the features of different embodiments can be mixed and matched with each other. Hence, while every permutation of features from different embodiments may not be explicitly shown, it is the intention of this specification to cover any such combinations.

This specification is generally directed to portable motorized fluid sprayers and methods of operation. Aspects of these portable motorized fluid sprayers may be useful in many different home and commercial environments, as well as particularly useful for military usage and environments.

For example, in the context of military usage, portable motorized fluid sprayers are sometimes used in remote locations, such as areas in proximity to combat. In that respect, such devices may be deployed out of land or aerial vehicles and may receive at least some impact. Additionally, remote locations often lack infrastructure, such as a supply of power or fuel, that may be used to continuously operate some devices.

Further, portable motorized fluid sprayers are sometimes used to apply chemicals with extreme properties, such as very high pH, very low pH, or chemicals with other potentially harmful side effects. For example, some decontamination solutions such as U.S. DoD Joint General Purpose Decontaminant (M333), have a relatively high pH while others, such as Clear Scientific Decontamination Slurry, may have a relatively low pH. Additionally, some fluids (e.g., decontamination solutions) may take the form of a slurry and therefore the solute can settle at the bottom of a tank of a sprayer over time. For example, some decontamination slurry contains abrasive slurry particles such as zirconium hydroxide. Similar problems may also present themselves in some commercial and home environments as well.

The features and embodiments described in this specification may be helpful in addressing some of these issues, as well as other issues.

Generally, the present specification includes a portable motorized fluid sprayer having a fluid tank and a manifold configured to pump fluid from the tank and into a connected fluid conveying structure (e.g., a hose, wand, nozzle, handle and/or similar structures). In one example, a manifold or pump manifold is defined as a structure that includes at least some components, but not necessarily all components, responsible for pumping fluid from the fluid tank and into the fluid conveying structure. In one example, the manifold may include an electric motor, a gear pump, a controller, and a battery (or an external power supply, such as a gas powered electrical generator).

The motorized fluid sprayer may be configured to be modular such that the manifold and its attached fluid conveying structure are removable and separable from the fluid tank. This allows the manifold to be separated and used with a different tank (e.g., a larger or different tank) if needed. Hence, the more expensive manifold portion may be cleaned and/or decontaminated and then reused with another tank, especially if the initial tank must be discarded. For example, the fluid tank may include a support structure, such as a bracket or shelf, onto which the manifold removably mounts. The manifold may be releasably secured with a variety of features, such as latches, mating grooves, mating pins/holes, screws, bolts, or any combination of these features. In one example, the support structure may form an “L” shaped shelf such that the manifold may be mounted to a relatively horizontal shelf portion. Alternatively, the manifold may be removably connected directly to the tank via an attachment mechanism (e.g., a rail and latch mechanism directly on the tank and manifold). The support structure may be permanently or removably fixed to the tank.

The fluid conveying structure (e.g., a hose, wand, nozzle, handle, and/or similar structures) may include several features that improve use and performance of the motorized fluid sprayer.

In one example, the motorized fluid sprayer is configured to deliver fluid through the fluid conveying structure at certain pressures without regard to the viscosity of the fluid. Hence, a user may be able to spray relatively high viscosity fluid (e.g., slurry), relatively low viscosity fluid (e.g., a water), or other fluids of various viscosities or other characteristics at the same pressure level. Additionally, this may be achieved with similar user actuation (e.g., the user depressing a lever to the same position results in the same pressure without regard to fluid viscosity).

In one example, the pressure regulation may be achieved with a fluid conveying structure that may include a handle with a user actuated fluid interface control connected to an electronic sensor. The fluid interface control may be a lever, a slider, a switch, one or more buttons, a thumbwheel, knob, or similar mechanisms that allow user input and adjustment. The electronic sensor may be one of a variety of different sensors, such as a Hall effect sensor that senses a position of a magnet connected to the fluid interface control such that as the user interface control is moved, the magnet also moves, which allows the Hall effect sensor to sense a change in the strength of the magnetic field of the magnet. While a variety of different sensor types are possible, a Hall effect sensor may be helpful at maintaining accurate sensor readings in the event that fluid penetrates near the sensor and/or fluid interface control. The Hall effect sensor may be used with a diametrically magnetized magnet (e.g., a cylindrical magnet with an axis along its length) that allows for simple mounting in the trigger while generating a simple magnetic field, allowing for a simple algorithm for positional detection of magnet versus hall sensor. Alternatively, an axially magnetized magnet may be used.

The electronic sensor senses the position of the fluid interface control and sends an electronic signal (e.g., an analog or digital signal) to a controller that controls the pressure of the fluid pumped out of the pump manifold. The controller may be electrically connected to an inline pressure sensor that senses pressure within the manifold fluid conduit connected to the fluid passage within the fluid conveying structure. The controller may also be electrically connected to an electric motor that is coupled to drive a pump that is also connected to the manifold fluid conduit connected to the fluid passage within the fluid conveying structure. Hence, the controller can receive electronic sensor signals and adjust the speed (and direction) of the electric motor to provide a specific fluid pressure to the fluid conveying structure. The controller therefore may include a table or formula stored in memory that looks up or converts a signal from the electronic sensor to a specific fluid pressure value sensed by the inline pressure sensor.

In another example aspect, a handle of the fluid conveying structure may include a safety control that must be activated for the fluid interface control to actuate fluid pumping via the pump manifold. If potentially hazardous or dangerous fluids are being used, the safety control helps prevent accidental discharge of that fluid. The safety control may be a variety of different mechanisms, such as a lever, switch, button, thumbwheel, slider, or similar mechanism. The safety control may also include an electric sensor in communication with the controller, and may also be a Hall effect sensor (e.g., with a magnet in the safety control) or other type of sensor.

In another example aspect, the fluid conveying structure may include a valve located within its fluid passage that allows fluid to flow out of the passage from the end of the fluid conveying structure when under pressure but otherwise closes when not under pressure. This may prevent fluid leftover in its passage from dripping from the fluid conveying structure, which may be helpful in circumstances when potentially damaging or hazardous chemicals are used with the motorized fluid sprayer. In that respect, the valve may be included in a handle portion or in a removable end nozzle attachment. The valve may be a ball valve, duck-bill valve, or similar type of valve. If located in the end nozzle attachment, this location allows the user to remove the valve when refilling the tank via the fluid conveying structure and handle.

In another example aspect, the motorized fluid pump may include a battery status indicator that communicates a charge level of a battery (e.g., a battery within and powering the pump manifold). The battery status indicator may be located on a handle of the fluid conveying structure, on the pump manifold, or on the fluid tank. The battery status indicator may be in electrical communication with the controller which powers and manipulates the battery status indicator to communicate a battery charge level. The battery status indicator may be a numerical display (e.g., LCD, transflective LCD, E-ink), a plurality of lights (e.g., an array of LEDs), or similar displays. This display may also be used for other information, such as the fluid pump's status (e.g., a ready status, a spray/fill status, or a recirculation status), pressure levels, temperature levels, fluid level in the tank, instructions, or similar information.

In another example aspect, the motorized fluid pump is reversible such that the opening/nozzle of the fluid conveying structure may be placed into fluid and that fluid sucked into the fluid tank. In examples where the motorized fluid pump is worn on the user's back (i.e., man-portable), such as similar to a backpack, the motorized fluid pump may be left on the user's back during a refilling process rather than removing the motorized fluid pump. This may allow faster refilling of the fluid tank and decrease the likelihood of spilling fluid when refilling. Further, the filled fluid tank is much heavier than an empty fluid tank and therefore a user may be able to more easily move an empty fluid pump to their back and then fill the fluid tank as opposed to moving a full fluid pump on their back. In one example, the previously described fluid interface control may be actuated to activate the pump mechanism in reverse. For example, if the fluid interface control is a lever, the lever may be moved in an opposite direction for fluid suction as opposed to fluid delivery.

In another example aspect, the pump manifold may include a gear pump driven by an electric motor. For example, the gear pump may include a housing and a single gear or two or more gears that are rotated to drive fluid flow. The gear pump may allow the pump manifold to reliably reverse directions (e.g., to provide fluid delivery or fluid suction into the fluid tank), may allow the pump to run without fluid (which can be helpful for cleaning purposes), and may be more resistant to harsh chemicals within the pumped fluid.

In another example aspect, the motorized fluid pump may be configured with a recirculation mode that recirculates fluid from the fluid tank, through the pump, and back into the fluid tank. This can be helpful with fluid in the tank that has a tendency to settle or that may otherwise need periodic mixing (e.g., a slurry). For example, the pump manifold may include a switch that switches a valve such that a fluid passage out of the pump may then be in communication with the fluid tank (e.g., the pump drains from one portion of the fluid tank and delivers fluid to another portion of the fluid tank). Hence, the fluid may be recirculated from and back into the fluid tank. The controller may be in communication with the switch and therefore aware of when it is set to the recirculate mode and therefore activate the pump to a desired pumping/pressure level, or the fluid interface control may be used to activate the recirculation.

The motorized fluid pump may also include one or more sensors at or near the fluid tank or fluid pathway. The one or more sensors may include temperature sensors, shock sensors, pressure sensors, capacitive sensors that sense conditions such as fluid level from an outside of the fluid tank and away from any harsh chemicals, or similar sensors. These sensors may be monitored by the controller and if, for example, the fluid solution stability conditions are exceeded (e.g., decontamination solution), the user can be made aware of potential decay or inefficiency of the decontaminant via a display audible alert or light (LED). In another example, if a fluid level sensor is provided for the fluid tank, refilling the tank via pump suction can be stopped as fluid reaches a top of the tank (e.g., the controller may monitor the level sensor and stop fluid suction into the tank). In addition, chemical, biological, or radio-nuclear sensors can also be integrated into the motorized fluid pump to alarm the user in case of a threat. While a hazard is likely expected during some hazardous usage and PPE is likely worn, notification and optional identification of the threat can aid the user to apply proper precaution and select appropriate decontamination steps and solutions.

In another example aspect, the fluid tank of the motorized fluid pump may be rigid or may be collapsible. In the case of a collapsible fluid tank, the tank may comprise a flexible material, such as a flexible plastic that, when empty, can be compressed to a smaller thickness (e.g., a generally flat or partially flat shape). This may allow the motorized fluid pump to occupy less space when not in use, which may be helpful when being stored or transported. Additionally, the smaller footprint may allow a user to more easily replace the tank with another tank without cross contamination.

illustrate various views of a motorized fluid pumpthat may include one or more of the previously described features. The motorized fluid pumpgenerally includes a pump manifold(), a fluid tank assembly(), a handle assembly(), a nozzle extension, and a fluid conveying structure(). Generally, the fluid tank assemblystores a fluid and the pump manifold pumps that fluid through the attached fluid conveying structure, through the handle assembly, and out the nozzle extension(optionally a nozzle may be attached directly to the handle assembly).

The fluid tank assemblyinclude a fluid tankwith an internal cavity for containing fluid. The fluid tankmay have an openingat its top surface that is sized to allow a user to pour fluid into the cavity of the fluid tankand which can be closed with a removable lid or cap that may include an air passage through its top to allow pressure equalization within the fluid tankduring use (e.g., air may enter or exit via the cap depending on whether the fluid pump is spraying or refilling the tank).

The fluid tankmay also include another openingB which may be removably connected to the pump manifold, as discussed later in further detail. The openingB may be located at a lower portion of the fluid tanksuch as a bottom surface or lower side surface, or at other locations such as an upper portion of the fluid tankwith a tube extending internally to a location near a bottom of the cavity of the fluid tank.

The fluid tankmay further include another openingA for accepting recirculated fluid drawn from the openingB, as discussed later in further detail. The openingA may be located at an upper portion of the fluid tank, such as an upper side as seen in the figures.

The fluid tankmay be rigid or may be rigid or may be partially or fully collapsible (e.g., capable of reducing its dimensions, such as thickness). In the case of a collapsible fluid tank, the tank may comprise a flexible material, such as a flexible plastic with an outer fabric layer that, when empty, can be at least partially compressed to a smaller thickness (e.g., a generally flat or partially flat shape). This may allow the motorized fluid pump to occupy less space when not in use, which may be helpful when being stored or transported. In one example, the flexible tank may include rigid structural supports connected with a rugged fabric and sealing layer.

The fluid tankmay further include a mixer within the cavity of the fluid tank. For example, the mixer may include a motor connected to a mixing structure (e.g., a helical mixing screw) that rotates within the cavity of the fluid tank.